Prismatic Electrochemical Cell

ABSTRACT

A method of manufacturing an electrochemical cell is provided. The cell includes a rigid housing and an electrode assembly disposed in the housing. The method includes providing a housing that includes a first end, a second end formed separately from the first end, and a tubular sidewall formed separately from each of the first end and the second end. After the electrode assembly is inserted into the sidewall, the first end is welded to one end of the sidewall, and the second end is welded to the other end of the sidewall.

BACKGROUND 1. Field of the Invention

The disclosure relates to an electrochemical cell that includes astacked arrangement of electrode plates, and more particularly to theorientation of the electrode plate and electrical connections of theelectrode plates relative to the cell housing. A method of manufacturingan electrochemical cell is also described.

2. Description of the Related Art

Battery packs provide power for various technologies ranging fromportable electronics to renewable power systems and environmentallyfriendly vehicles. For example, hybrid electric vehicles (HEV) use abattery pack and an electric motor in conjunction with a combustionengine to increase fuel efficiency. Battery packs can be formed of aplurality of battery modules, where each battery module includes severalelectrochemical cells. Within the battery modules, the cells arearranged in two or three dimensional arrays and are electricallyconnected in series and/or in parallel. Likewise, the battery moduleswithin a battery pack are electrically connected in series and/or inparallel.

Different cell types have emerged in order to deal with the spacerequirements of a very wide variety of installation situations, and themost common types used in automobiles are cylindrical cells, prismaticcells, and pouch cells. Regardless of cell type, each cell may include acell housing and an electrode assembly disposed in the cell housing. Theelectrode assembly includes an alternating series of stacked or rolledpositive electrode plates and negative electrode plates that areseparated by an intermediate separator material. Each cell may alsoinclude a first current collector that is electrically connected to thepositive electrode plates and joins the positive electrode plates to apositive cell terminal disposed outside the cell housing, and a secondcurrent collector that is electrically connected to the negativeelectrode plates and joins the negative electrode plates to a negativecell terminal disposed outside the cell housing. Due to the large numberof cells used to provide the required power output, vehicle batterypacks tend to be large and thus the volume efficiency of the componentsof a battery system including the cell becomes important. A need existsfor improved usage of the internal volume of a cell.

SUMMARY

In some aspects, a method of manufacturing an electrochemical cell isprovided. The cell includes a rigid cell housing having the shape of arectangular prism and an electrode assembly disposed in the cellhousing. The method includes the following steps: Providing a cellhousing first end; providing a cell housing second end; providing a cellhousing sidewall in the form of a tube having a rectangularcross-sectional shape, the cell housing sidewall formed separately fromeach of the cell housing first end and the cell housing second end;inserting the electrode assembly into the cell housing sidewall; weldingthe cell housing first end to one end of the cell housing sidewalk andwelding the cell housing second end to an end of the cell housingsidewall opposed to the one end of the cell housing sidewall.

The method may include one or more of the following method steps and/orfeatures: The electrode assembly includes positive electrode platesalternating with negative electrode plates and separated by at least oneseparator to form an electrode stack. The electrode assembly defines astack axis that extends parallel to a stacking direction of the positiveelectrode plates, the negative electrode plates and the at least oneseparator. The cell housing sidewall includes a pair of major sidesjoined by a pair of minor sides, where each side of the pair of majorsides is larger in area than each side of the pair of minor sides. Inaddition, the step of inserting the electrode assembly into the cellhousing sidewall includes orienting the electrode stack within the cellhousing such that the stack axis extends in a direction that is normalto, and passes through, each side of the pair of minor sides. Theelectrochemical cell comprises a connector disposed in the cell housingbetween the electrode assembly and the cell housing first end, and themethod includes electrically connecting one end of the connector to aterminal that protrudes through the cell housing first end; electricallyconnecting another end of the connector to an electrode plate of theelectrode assembly; folding the connector such that the one end of theconnector overlies the another end of the connector, and such that thecell housing first end abuts the one end of the cell housing sidewalk.The method steps that include electrically connecting one end of theconnector to a terminal that protrudes through the cell housing firstend; electrically connecting another end of the connector to anelectrode plate of the electrode assembly; and folding the connectorsuch that the one end of the connector overlies the another end of theconnector, and such that the cell housing first end abuts the one end ofthe cell housing sidewall, are performed before the method step ofwelding the cell housing first end to one end of the cell housingsidewall.

The method may also include one or more of the following method stepsand/or features: The electrode assembly includes positive electrodeplates alternating with negative electrode plates and separated by atleast one separator. Each of the positive electrode plates include anelectrically conductive first substrate; a first coating disposed on thefirst substrate, where the first coating is formed of a first activematerial; a first clear lane that is disposed along an edge of thepositive electrode plate, the first clear lane being free of the firstcoating; and a first opening disposed within the first clear lane. Eachof the negative electrode plates include an electrically conductivesecond substrate; a second coating disposed on the second substrate,where the second coating is formed of a second active material; a secondclear lane that is disposed along an edge of the negative electrodeplate, the second clear lane being free of the second coating; and asecond opening disposed within the second clear lane. In addition, themethod includes the following method steps: inserting an electricallyconductive first inner plate through each first opening such that thefirst inner plate extends in a direction perpendicular to each positiveelectrode plate, and is electrically connected to at least one of thepositive electrode plates, and inserting an electrically conductivesecond inner plate through each second opening such that the secondinner plate extends in a direction perpendicular to each negativeelectrode plate, and is electrically connected to at least one of thenegative electrode plates. The method includes folding each positiveelectrode plate along a first fold line that extends along a margin ofthe opening, whereby the first clear lane overlies a side of theelectrode stack and the first inner plate; and folding each negativeelectrode along a second fold line that extends along a margin of theopening, whereby the second clear lane overlies a side of the electrodestack and the second inner plate. The method includes disposing anelectrically conductive first outer plate over folded first clear lanessuch that the first outer plate overlies the first inner plate and thefirst clear lanes are disposed between the first outer plate and thefirst inner plate, and disposing an electrically conductive second outerplate over folded second clear lanes such that the second outer plateoverlies the second inner plate and the second clear lanes are disposedbetween the second outer plate and the second inner plate. The methodincludes welding the first inner plate, the folded first clear lanes,and the first outer plate together to form an electrical connectionbetween the first inner plate, the folded first clear lanes, and thefirst outer plate, and welding the second inner plate, the folded secondclear lanes, and the second outer plate together to form an electricalconnection between the second inner plate, the folded second clearlanes, and the second outer plate. The method includes electricallyconnecting the first outer plate to a terminal that protrudes throughthe cell housing and is electrically isolated from the cell housing, andelectrically connecting the second outer plate to the cell housing.

The method may also include one or more of the following method stepsand/or features: A first connector is used to electrically connect thefirst outer plate to the terminal, and a second connector is used toelectrically connect the second outer plate to the cell housing. Aconnector is used to electrically connect the first outer plate to theterminal, and the second outer plate is electrically connected to thecell housing via direct contact with the cell housing. The electrodeassembly comprises positive electrode plates alternating with negativeelectrode plates and separated by at least one separator, each of thepositive electrode plates and the negative electrode plates including anelectrically conductive substrate; a coating disposed on the substrate,where the coating is formed of an active material; a clear lane that isdisposed along an edge of the substrate, the clear lane being free ofthe coating; and an opening disposed within the clear lane, and themethod includes the following method step: inserting an electricallyconductive inner plate through each opening of at least one of thepositive electrode plates and the negative electrode plates such thatthe inner plate extends in a direction perpendicular to each substrate,and is electrically connected to the substrate. The method includesfolding each electrode plate of the at least one of the positiveelectrode plates and the negative electrode plates along a first foldline that extends along a boundary between the coating and the clearlane, whereby the clear lane overlies a side of the electrode stack andthe inner plate. The method includes disposing an electricallyconductive outer plate over the folded clear lanes such that the outerplate overlies the inner plate and the clear lanes are disposed betweenthe outer plate and the inner plate. The method includes welding theinner plate, the folded clear lanes, and the outer plate together toform an electrical connection between the inner plate, the folded clearlanes, and the outer plate. The method includes electrically connectingthe outer plate to one of a cell housing and a terminal that protrudesthrough the cell housing, where the terminal is electrically isolatedfrom the cell housing. A connector is used to electrically connect theouter plate to the one of a cell housing and a terminal. The first end,the second end and the sidewall are provided as three individual andseparate elements, the electrode assembly includes positive electrodeplates alternating with negative electrode plates and separated by atleast one separator to form an electrode stack, the electrode assemblyincludes a first current collector including a first connector thatelectrically connects the positive electrode plates to a positiveterminal, and the electrode assembly includes a second current collectorincluding a second connector that electrically connects the negativeelectrode plates to a negative terminal. The second end and the sidewallare provided as a single integral entity, and the first end is providedas a separate element from the integral sidewall and second end, theelectrode assembly includes positive electrode plates alternating withnegative electrode plates and separated by at least one separator toform an electrode stack, the electrode assembly includes a first currentcollector including a first connector that electrically connects one ofthe negative electrode plates and the positive electrode plates to firstterminal, and the electrode assembly includes a second current collectorthat is connector free and forms a weld-free electrical connectionbetween the other one of the the negative electrode plates and thepositive electrode plates and a second terminal.

In some aspects, a prismatic electrochemical cell includes an electrodeassembly disposed in a rigid cell housing in such a way as to provideimproved efficiency of use of the internal volume of the cell housing byproviding an improved electrode arrangement and orientation within thecell housing.

In some aspects, the cell includes a rigid prismatic cell housingincluding a first end, a second end and a sidewall that connects thefirst end to the second end. The sidewall is a tube having a rectangularcross sectional shape, and includes a pair of major sides joined by apair of minor sides, where each side of the pair of major sides islarger in area than each side of the pair of minor sides. The electrodeassembly disposed in the housing includes a stacked arrangement ofelectrode plates. The electrode assembly is oriented within in the cellhousing so that the stacking direction of the electrode plates isparallel to an axis that is normal to, and passes through, each side ofthe pair of minor sides. Use of stacked rectangular electrode platesadvantageously permits improved filling of the internal volume of theprismatic cell as compared to use of a jelly-roll electrodeconfiguration within a prismatic cell. In addition, by orienting theelectrode plates so as to be perpendicular to the major sides of thecell housing, outward bulging of the major sides of the cell housing dueto cell growth is reduced as compared to prismatic cells including ajelly roll electrode assembly, and as compared to prismatic cellsincluding a stacked electrode assembly in which the electrode plates areoriented parallel to the major sides of the cell housing.

In some aspects, the cell includes terminals that provide a largesurface as an electrical contact area. The electrical contact area is anoutward facing surface that is parallel to the surface of the cellhousing from which the terminal protrudes. In some embodiments, theterminal is sized such that the electrical contact area is in a range of20 to 90 percent of an area of the surface of the cell housing fromwhich the terminal protrudes. In addition, the terminals are low profilein that the dimensions of the electrical contact area are greater thanthe height of the terminal. By providing a terminal in which the contactsurface is parallel to the surface of the cell housing from which theterminal protrudes, and by providing the contact surface as a relativelylarge area, it is possible to form an electrical connection betweenadjacent cells of a cell pack or between a cell and the module or packhousing via direct pressure contact, whereby use of bus bars and othertypes of electrical connectors can be reduced or avoided altogether.

In some aspects, a method of manufacturing an electrochemical cell isprovided in which the cell housing is formed of separate elements thatare welded together. In some embodiments, the cell housing includes afirst end, a second end, and a tubular sidewall that are each formedseparately. After insertion of the electrode assembly into the cellhousing, the first end and the second end are attached to the respectiveends of the sidewall using a welding process. This can be compared tosome conventional cylindrical cell housings in which the tubularsidewall and second end are formed integrally for example in a pressingprocess, and the first end is attached to the sidewall via a crimpingprocess. Use of welding to connect the ends to the sidewall in aprismatic cell is advantageous since it is difficult to provide areliable crimp at the corner portions of the prismatic housing.

During manufacture of the cell, the electrode assembly is placed withinthe sidewall, and the negative electrode plates are electricallyconnected to one end (for example the cell housing first end) prior tothe one end being joined to the sidewall. In addition, the positiveelectrode plates may be electrically connected to the other end (forexample the cell, housing second end) prior to the other end beingjoined to the sidewall. The electrical connections may be achieved, forexample, by welding or other appropriate technique. Since both ends ofthe tubular sidewall are open, and since the cell housing first andsecond ends are not yet joined to the sidewall, electrical connection ofboth the negative electrode plates to the first end and the positiveelectrode pates to the second end is simplified and has improvedreliability as compared to forming such a welded connection at a blindend of a container.

In some aspects, a terminal protrudes through one end (for example thefirst end) of the cell housing. The electrical connection between theelectrode plates and the terminal is made using a foldable electricalconnector and is performed prior to attachment of the first end to thehousing sidewall. The electrical connector facilitates use of a weldingprocess to connect one end of the connector to the terminal and anopposed end of the connector to an electrode plate while the first endis separate from the sidewall. In addition, the electrical connectorfacilitates assembly of the first end with the sidewall so that thewelding step can be performed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the elements of a battery pack, where the elements ofthe battery back are shown in perspective view.

FIG. 2 is an exploded perspective view of a cell of the battery pack ofFIG. 1.

FIG. 3 is a schematic cross-sectional view of a portion of the electrodestack of the cell of FIG. 2, including a detail plan view of an isolatedpositive electrode plate and an isolated negative electrode plate.

FIG. 4 is a schematic perspective view of the cell illustrating theorientation of the electrode plates within the cell housing.

FIG. 5 is a perspective view of a portion of an electrode plateillustrating a folded clear lane.

FIG. 6 is a perspective view of a portion of the electrode stackillustrating the overlapping louvered configuration of electrode platesof a common polarity. The current collector assembly is omitted fromthis figure to permit visualization of the openings in each electrodeplate.

FIG. 7 is an exploded perspective view of the electrode assembly of thecell.

FIG. 8 is a side view of the electrode assembly of the cell.

FIG. 9 is an exploded perspective view of the first current collectorassembly.

FIG. 10 is an exploded perspective view of the second current collectorassembly.

FIG. 11 is a perspective view of a portion of the electrode stackillustrating the overlapping louvered configuration of electrode platesof a common polarity. The inner plate of the current collector assemblyis included in this figure.

FIG. 12 is a perspective view of a portion of the electrode stackillustrating the overlapping louvered configuration of electrode platesof a common polarity. The inner plate and the outer plate of the currentcollector assembly are included in this figure.

FIG. 13 is an exploded perspective view of the pair of terminals.

FIG. 14 is a side cross-sectional view of the pair of terminals.

FIG. 15 is a perspective view of the insert.

FIG. 16 is a perspective cross-sectional view of a portion of the cellas seen along line 16-16 of FIG. 1, with the electrode stack omitted forclarity.

FIG. 17 is a perspective cross-sectional view of a portion of the cellas seen along line 17-17 of FIG. 1, with the electrode stack omitted forclarity with the exception of a single positive electrode plate and asingle negative electrode plate.

FIG. 18A and FIG. 18B are a flow diagram illustrating a method ofmanufacturing a cell.

FIG. 19 is a schematic cross-sectional view of a portion of theelectrode stack illustrating the method step of inserting the first andsecond inner plates into the openings of the electrode plates prior tofolding the clear lanes. The separator is omitted and only a subset ofelectrode plates are illustrated for clarity.

FIG. 20 is a perspective view of the cell during manufacture thereof,illustrating the cell housing configuration prior to folding of thefirst and second connectors.

FIG. 21 is an exploded perspective view of a cell including analternative embodiment cell housing.

FIG. 22 is a perspective view of the cell housing first end illustratingan alternative embodiment terminal configuration.

FIG. 23 is a perspective view of an alternative embodiment electricalconnection between the terminals and the current collector assembly.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a battery pack 1 used to provide electricalpower includes electrochemical cells 20 that are electricallyinterconnected and stored in an organized manner within a battery packhousing 2. The battery pack housing 2 includes a pack container portion4 and a detachable pack lid (not shown). The cells 20 are lithium-ioncells that include an electrode assembly 60 that is sealed within a cellhousing 22 along with an electrolyte to form a power generation andstorage unit. In some embodiments, groups of cells 20 may be bundledtogether to form battery modules 8, which in turn are stored within thebattery pack housing 2. Within the battery pack housing 2, the cells 20are electrically connected in series and/or in parallel.

Each cell 20 includes a prismatic cell housing 22. As used herein, theterm “prismatic” refers to the shape of cell housing 22, andparticularly refers to having a rectangular shape. In the illustratedembodiment, the cell housing 22 includes an elongated rectangular firstend 23 which supports a pair of terminals 140, 142, and an elongatedrectangular second end 24 that is spaced apart from, and parallel to,the first end 23. The cell housing 22 includes a sidewall 25 that joinsthe first end 23 to the second end 24. The sidewall 25 is a tube havinga rectangular cross-sectional shape. The sidewall 25 is formedseparately from each of the first and second ends 23, 24. The sidewall25 includes a pair of major sides 26, 27 joined by a pair of minor sides28, 29. The second major side 27 is spaced apart from, and parallel to,the first major side 26. The second minor side 29 is spaced apart from,and parallel to, the first minor side 28. In addition, each side 26, 27of the pair of major sides is larger in area than each side 28, 29 ofthe pair of minor sides. The first end 23, the second end 24 and thesidewall 25 together define a sealed interior space occupied by theelectrode assembly 60.

The cell housing 22 has a length l_(c) that extends in parallel to thefirst major side 26 and a thickness t_(c) that extends in parallel tothe first minor side 28. The cell housing 22 has a height he that isperpendicular to both the length l_(c) and the thickness t_(c), andcorresponds to the spacing between the first and second ends 23, 24. Insome embodiments, the ratio of the length l_(c) to the thickness t_(c)is in a range of 2:1 to 5:1. For example, in the illustrated embodiment,the ratio of the length l_(c) to the thickness t_(c) is 3.0. The heighthe of the cell housing 22 is limited only by the requirements of thespecific application. In the illustrated embodiment, the ratio of thelength l_(c) to the height is 1.3.

The cell housing 22 is formed of an electrically conductive material,such as metal. Thus, the cell housing 22 is rigid as compared to someother types of electrochemical cell housings such as pouch-type cellhousings that are formed of a flexible laminate material.

Referring to FIGS. 3 and 4, the electrode assembly 60 is disposed in thecell housing 22 and includes a series of stacked positive electrodeplates 61 alternating with negative electrode plates 62 and separated byan intermediate z-folded separator 63.

Each of the positive and negative electrode plates 61, 62 may have alayered structure to facilitate insertion and/or movement oflithium-ions. For example, in the illustrated embodiment, the positiveelectrode plate 61 includes a first substrate 50 formed of a firstelectrically-conductive material such as aluminum. In addition, thepositive electrode plate 61 includes a coating formed of a first activematerial 53 such as a litigated metal oxide disposed on both sides 51,52 of the first substrate 50. The first active material 53 is appliedfor example in a slurry coating process, printing process or otherappropriate process. The first active material 53 covers the sides 51,52 of the positive electrode plate 61 except within a narrowcoating-free region along one lengthwise edge 54 of the positiveelectrode plate 61, whereby a positive clear lane 56 of bare substrateis provided along the lengthwise edge 54 of the positive electrode plate61. The positive clear lane 56 is electrically conductive and free ofactive material. Each positive electrode plate 61 includes an opening 58disposed in the positive clear lane 56. The opening 58 is elongated inthe lengthwise direction, and is closer to the boundary 57 between thefirst active material 53 and the plate lengthwise edge 54 than to theplate lengthwise edge 54. The opening 58 receives a portion of a firstcurrent collector assembly 80, as discussed in detail below.

The negative electrode plate 62 includes a second substrate 70 formed ofa second electrically-conductive material such as copper. In addition,the negative electrode plate 62 includes a coating formed of a secondactive material 73 such as graphite disposed on both sides 71, 72 of thesecond substrate 70. The second active material 73 is applied forexample in a slurry coating process, printing process or otherappropriate process. The second active material 73 covers the sides 71,72 of the negative electrode plate 62 except within a narrowcoating-free region along one lengthwise edge 74 of the negativeelectrode plate 62, whereby a negative clear lane 76 of bare substrateis provided along the lengthwise edge 74 of the negative electrode plate62. The negative clear lane 76 is electrically conductive and free ofactive material. Each negative electrode plate 62 includes an opening 78disposed in the negative clear lane 76. The opening 78 is elongated inthe lengthwise direction, and is closer to the boundary 77 between thesecond active material 73 and the plate lengthwise edge 74 than to theplate lengthwise edge 74. The opening 78 receives a portion of a secondcurrent collector assembly 90, as discussed in detail below.

Each of the positive and negative electrode plates 61, 62 are elongatedrectangular plates. The electrode plates 60. 61 are very thin, and thusare often referred to as foils. For example, in the illustratedembodiment, the electrode plates 60, 61 have a substrate thickness ofabout 0.012 mm, and a coated thickness t_(p) of about 0.108 mm. Theelectrode plates 60, 61 have a plate length l_(p) that is much greaterthan the plate thickness t_(p), having for example a plate length l_(p)on the order of tens of mm. The plate height h_(p) is determined by theheight he of the cell housing 22, and thus may also be on the order oftens of mm. In the illustrated embodiment, the electrode plates 60, 61have a plate height h_(p) that is greater than the plate length l_(p).For example, in some embodiments, the ratio of plate height h_(p) toplate length l_(p) is about 2:1.

The separator 63 is a permeable membrane that functions to keep thepositive and negative electrode plates 61, 62 apart to preventelectrical short circuits while also allowing passage of ionic chargecarriers provided in the electrolyte and that are needed to close thecircuit during the passage of current within the cell 20. The separator63 is formed of, for example, an electrically insulating material suchas a trilayer polypropylene-polyethylene-polypropylene membrane.

During stacking of the electrode assembly 60, the positive electrodeplates 61, the negative electrode plates 62 and the separator 63 thatform the electrode assembly 60 are arranged in a layered or stackedconfiguration in the stacking direction. The series of stacked electrodeplates 61, 62 and separator 63 will be referred to herein as the“electrode stack” 64, and a stack axis 66 of the electrode stack 64extends through a center of the electrode stack 64 in a directionparallel to the stacking direction and perpendicular to the coatedsurfaces 51, 52, 71, 72 of the electrode plates 61, 62. A portion of theelectrode stack 64 is shown schematically in FIG. 3. In the stackedconfiguration, the separator 63 is folded in a Z configuration such thatperipheral edges and the folds of the separator 63 are aligned in adirection parallel to the stack axis 66.

The positive and negative electrode plates 61, 62 are disposed inalternating folds of the separator 63 so as to be parallel and overlieeach other. In addition, the positive and negative electrode plates 61,62 are partially offset in a direction transverse to the stack axis andin the height direction of the electrode plate relative to therespective separator 63. In particular, the positive electrode plates 61are stacked along the stack axis 66 such that peripheral edges of thepositive electrode plates 61 are aligned with each other in a directionparallel to the direction of the stack axis 66 but are partially offsetrelative to the separator 63 in a first direction parallel to the heightdirection. The first direction is represented in FIG. 3 by arrow 37. Inparticular, the positive electrode plate 61 is arranged relative to theseparator 63 such that the positive clear lane 56 of each of thepositive electrode plates 61 extends beyond a corresponding edge 63 a ofthe separator 63.

The negative electrode plates 62 are stacked along the stack axis 66such that peripheral edges of the negative electrode plates 62 arealigned with each other in a direction parallel to the direction of thestack axis 66 but are partially offset relative to the separator 63 in asecond direction, where the second direction is parallel to the heightdirection and opposed to that of the first direction. The seconddirection is represented in FIG. 3 by arrow 38. In particular, thenegative electrode plate 62 is arranged relative to the separator 63such that the negative clear lane 76 of each of the negative electrodeplates 62 extends beyond a corresponding edge 63 b of the separator 63.

When the electrode assembly 60 is disposed in the cell housing 22, thepositive electrode plate 61 is offset relative to the separator 63toward the cell housing second end 24, and the negative electrode plate62 is offset relative to the separator 63 toward the cell housing firstend 23. In addition, the separator 63 is oriented so that the fold edges65 of the separator 63 abut the major sides 26, 27 of the cell housing20 and extend between the cell housing first and second ends 23, 24. Theelectrode plates 61, 62 are disposed in the folds of the separator 63 sothat the coated surfaces 51, 52, 71, 72 of the electrode plates 61, 62are parallel to the cell housing minor sides 28, 29 and so that thestack axis 66 extends in a direction perpendicular to the cell housingminor sides 28, 29.

Referring to FIGS. 5-6, the clear lane 56 of each positive electrodeplate 61 is folded against a side of the electrode stack 64. Likewise,the clear lane 76 of each negative electrode plate 62 is folded againstthe opposed side of the electrode stack 64. As seen in FIG. 5, the clearlanes 56, 76 are folded along an outer margin of the opening 58, 78(FIG. 5 shows only the negative electrode plate 62). Due to the relativespacing of the individual electrode plates 61, 62 along the stack axis66, the folded clear lanes 56, 76 form an overlapping louveredconfiguration in which a portion of each clear lane 56, 76 is exposedand faces an inner side of the cell housing 22. The folded clear lanes56, 76 on a given side of the electrode stack 64 cooperate to form agenerally planar electrically conductive surface 69 that can be used toform an electrical connection with a corresponding current collectionassembly 80, 90 as discussed further below.

Referring again to FIG. 2, the electrode assembly 60 may optionallyinclude insulating band 68 that tightly encircles the electrode stack64. As a result, the insulating band 68 is disposed between theelectrode stack 64 and the sidewall 25. In this configuration, the clearlanes 56, 76 are not enclosed by the insulating band 68, and insteadprotrude from, and are exposed at, opposed open ends of the insulatingband 68. The insulating band 68 maintains the electrode stack 64 in acompressed state in a direction parallel to the stack axis 66, andfacilitates insertion of the electrode stack 64 into the cell housing 22during cell assembly, as discussed further below.

Referring to FIGS. 7 and 8, the electrode assembly 60 also includes afirst current collector assembly 80 and a second current collectorassembly 90 that form an electrical connection with the electrode plates61, 62 of the electrode stack 64. The first current collector assembly80 is disposed between the electrode stack 64 and the cell housingsecond end 24, and forms an electrical connection with the positiveelectrode plates 61 of the electrode assembly 60. The second currentcollector assembly 90 is on the opposed side of the electrode stack 64so as to be disposed between the electrode stack 64 and the cell housingfirst end 23, and forms an electrical connection with the negativeelectrode plates 62 of the electrode assembly 60.

Referring to FIG. 9, the first current collector assembly 80 includes anelectrically conductive first inner plate 81 and an electricallyconductive first outer plate 84 that is parallel to the first innerplate 81. The first inner plate 81 and the first outer plate 84 areformed of the same material as the first substrate 50 used to form thepositive electrode plates 61. The first inner plate 81 has a rectangularcross-section that is dimensioned to be slightly smaller than theopenings 58 of the positive electrode plates 61. The first inner plate81 extends through the opening 58 of each of the positive electrodeplates 61. In addition, the first inner plate 81 is disposed betweeneach of folded portions of the positive clear lanes 56 and the electrodestack 64. This is achieved, for example, by sliding the opening 58 ofeach positive electrode plate 61 onto the first inner plate 81 duringelectrode plate stacking, and prior to folding the positive clear lanes56.

The first outer plate 84 overlies the first inner plate 81 such that thefolded positive clear lanes 56 are disposed between, and form anelectrical connection with, the first outer plate 84 and the first innerplate 81. In the illustrated embodiment, the first outer plate 84, thefirst inner plate 81 and the folded portions of the positive clear lanes56 are electrically connected via welding.

In some embodiments, an insulating sheet 88 is disposed between thefirst inner plate 81 and an inner margin of the positive electrode plateopening 58 to prevent an electrical short circuit between the firstinner plate 81 and a peripheral edge of the negative electrode plates62. In some embodiments, the insulating sheet 88 may be an electricallyinsulating adhesive tape that is secured to the inward-facing (e.g.,electrode stack-facing) side 85 of the first inner plate 81.

The first current collector assembly 80 also includes a first connector100 that is used to form the electrical connection between the firstouter plate 84 and the cell housing second end 24. The first connector100 is disposed in the cell housing 22 between the first outer plate 84and the cell housing second end 24. The first connector 100 is formed ofan elongated, electrically conductive strip of material that ispartially folded along fold lines that are parallel to the direction ofstrip elongation and segregate the first connector 100 into portions. Inparticular, the first connector 100 includes a first leg portion 101that is connected to a second leg portion 102 via a base portion 103.Prior to assembly within the cell housing, the first and second legportions 101, 102 are each at an obtuse angle relative to the baseportion 103 (FIGS. 7-9), whereby the first connector 100 has a splayed Ushape when seen in cross-section. The first leg portion 101 iselectrically connected, for example by welding, to the first outer plate84. In addition, the second leg portion 102 is electrically connected,for example by welding, to the cell housing second end 24. Theelectrical connection is made, prior to connection of the cell housingsecond end 24 to the tubular sidewall 25, and thus the splayed U shapeconfiguration of the first connector 100 facilitates access to thesurfaces to be welded. As discussed further below, when the firstcurrent collector assembly 80 is assembled within the cell housing 22,the base portion 103 is further folded such that the second leg portion102 closely overlies and is parallel to the first leg portion 101 toform a flattened U-shape configuration (not shown). In addition, thefold of the base portion 103 extends in parallel to the major sides 26,27 of the cell housing 22. Since first and second legs 101, 102 of thefirst connector 100 have relatively large surfaces, the area ofelectrical connection between the first outer plate 84 and the firstconnector 100, and the area of electrical connection between the firstconnector 100 and the housing second end 24 can each be made large. Inaddition, since the first connector 100 is folded into the flattenedU-shape configuration during assembly, the first connector 100 is madecompact while providing a large electrical connection area. In theillustrated embodiment, the first current collector assembly 80 iselectrically connected to the positive electrode plates 61, whereby thecell housing 22 has a positive electrical polarity and serves as thepositive terminal of the cell 20.

Referring to FIGS. 10-12, like the first current collector assembly 80,the second current collector assembly 90 includes an electricallyconductive second inner plate 91 and an electrically conductive secondouter plate 94 that is parallel to the second inner plate 91. The secondinner plate 91 and the second outer plate 94 are formed of the samematerial as the second substrate 70 used to form the negative electrodeplates 62. The second inner plate 91 has a rectangular cross-sectionthat is dimensioned to be slightly smaller than the openings 78 of thenegative electrode plates 62. The second inner plate 91 extends throughthe openings 78 of each of the negative electrode plates 62 (FIG. 11).In addition, the second inner plate 91 is disposed between each offolded portions of the negative clear lanes 76 and the electrode stack64. This is achieved, for example, by sliding the opening 78 of eachnegative electrode plate 62 onto the second inner plate 91 duringelectrode plate stacking, and prior to folding the negative clear lanes76.

The second outer plate 94 overlies the second inner plate 91 such thatthe folded negative clear lanes 76 are disposed between, and form anelectrical connection with, the second outer plate 94 and the secondinner plate 91 (FIG. 12). In the illustrated embodiment, the secondouter plate 94, the second inner plate 91 and the folded portions of thenegative clear lanes 76 are electrically connected for example viawelding.

In some embodiments, an insulating sheet 98 is disposed between thesecond inner plate 91 and an inner margin of the negative electrodeplate opening 78 to prevent an electrical short circuit between thesecond inner plate 91 and a peripheral edge of the positive electrodeplates 61. In some embodiments, the insulating sheet 98 may be anelectrically insulating adhesive tape that is secured to theinward-facing (e.g., electrode stack-facing) side 95 of the second innerplate 91.

The second current collector assembly 90 also includes a second,connector 120 that is used to form the electrical connection between thesecond outer plate 94 and each of the terminals 140, 142. The secondconnector 120 is disposed in the cell housing 22 between the secondouter plate 94 and the cell housing first end 23. The second connector120 is formed of an elongated, electrically conductive strip of materialthat is partially folded along a fold line that is parallel to thedirection of strip elongation and segregates the second connector 120into leg portions. In particular, the second connector 120 includes afirst leg portion 121 that is connected to a second leg portion 122 viathe fold, which corresponds to a base portion 123. Prior to assemblywithin the cell housing, the first and second leg portions 121, 122 areeach at an obtuse angle relative to the base portion 123 (not shown),whereby the second connector 120 has a splayed U shape when seen incross-section. Material is removed from a central portion of the baseportion 123 and second leg 122, whereby the second leg portion 122 formsa pair of spaced tabs 122 a, 122 b. The first leg portion 121 iselectrically connected, for example by welding, to the second outerplate 94. In addition, the second leg portion 122 is electricallyconnected, for example by welding, to each of the terminals 140, 142.More specifically, the first tab 122 a is connected to the firstterminal 140, and the second tab 122 b is connected to the secondterminal 142. The electrical connections are made prior to connection ofthe cell housing first end 23 to the tubular sidewall 25, and thus thesplayed U shape configuration of the second connector 120 facilitatesaccess to the surfaces to be welded. As discussed further below, whenthe second current collector assembly 90 is assembled within the cellhousing 22, the base portion 123 is further folded such that the secondleg portion 122 closely overlies and is parallel to the first legportion 121 to form a flattened U-shape configuration (FIG. 10). Inaddition, the fold of the base portion 123 extends in parallel to themajor sides 26, 27 of the cell housing 22. Since first and second legs121, 122 of the second connector 120 have relatively large surfaces, thearea of electrical connection between the second outer plate 84 and thesecond connector 120, and the area of electrical connection between thesecond connector 120 and the respective terminals 140, 142 can each bemade large. In addition, since the second connector 120 is folded intothe flattened U-shape configuration during assembly, the secondconnector 120 is made compact while providing a large electricalconnection area. In the illustrated embodiment, the second currentcollector assembly 90 is electrically connected to the negativeelectrode plates 62, whereby the terminals 140, 142 each have a negativeelectrical polarity.

The first and second inner plates 81, 91 have a thickness that isgreater than the thickness of the first and second outer plates 84, 94,and a width that is slightly less than the width of the openings 58, 78in the electrode plates 61, 62. In some embodiments, the ratio of thethickness time, of the first inner plate 81 or second inner plate 91 tothe thickness touter of the first outer plate 84 or second outer plate94 is in a range of 2:1 to 4:1. For example, in the illustratedembodiment, the first inner plate 84 has a thickness of about 0.75 mmand the first outer plate 81 has a thickness of about 0.25 mm, wherebythe ratio of timer to touter is about 3:1. By sandwiching the foldedclear lanes 56, 76 between the respective inner plates 81, 91 and outerplates 84, 94, it is possible to weld the electrode plates 61, 62 to theinner and outer plates 81, 91, 84, 94 without burning the electrodeplates away via the heat of the welding process. In addition, byproviding the first and second inner plates 81, 91 with a greaterthickness than the first and second outer plates 84, 94, it is possibleachieve reliable welding of the outer plates to the inner plates withoutdamaging the coated portions of the electrode plates 61, 62, since theinner plates 81, 91 serve as a relative heat sink.

Referring to FIGS. 13 and 14, as previously discussed, the secondcurrent collector assembly 90 is electrically connected to the pair ofelectrically conductive terminals 140, 142. Each terminal 140, 142 ofthe pair of terminals is identical, whereby only one terminal 140 willbe described in detail, and common reference numbers will be used torefer to common elements.

The terminal 140 protrudes through the cell housing first end 23, andincludes an external contact portion 141 that is electrically conductiveand serves as an external electrical contact of the cell 20. Theterminal 140 includes an electrically conductive internal contactportion 170 that provides an electrical connection between the externalcontact portion 141 and the second outer plate 94. In particular, theexternal contact portion 141 includes a contact plate 144 having anoutward facing surface 146 and an opposed inward-facing surface 148. Apost 150 protrudes from the inward facing surface 148. The post 150 isreceived within, and forms an electrical connection with, an opening 178formed in the internal contact portion 170.

The terminal 140 is electrically isolated from the cell housing firstend 23. To that end, the terminal 140 includes an external insulatingseat 152 that receives the external contact portion 141 and separates itfrom an outer surface of the cell housing first end 23, and an internalinsulating seat 160 that receives the internal contact portion 170 andseparates it from the inner surface of the cell housing first end 23. Acollar 164 protrudes from an outward-facing surface of the internalinsulating seat 160. The collar 164 receives the post 150 and abuts thecontact plate inward-facing surface 148. To this end, the collar 164passes through respective openings 35, 158 in the cell housing first end35 and the external insulating plate 154, whereby the terminal 140 iselectrically isolated from the cell housing first end 23. Each of theexternal insulating seat 152 and the internal insulating seat 160 areformed of an electrically insulating material.

The contact plate 144 of the terminal 140 is generally rectangular inshape, and provides a contact surface (e.g., outward facing surface 146)that is parallel to the cell housing first end 23. The area of thecontact plate outward facing surface 146 is large relative to the areaof the cell housing first end 23. For example, the area of the outwardfacing surface 146 may be fifteen to forty percent of the area of thecell housing first end 23. In addition, a dimension (for example, lengthor width) of the outward facing surface 146 is greater than thedimension of the terminal 140 in a direction perpendicular to the firstend 23 (for example, height), whereby the terminal 140 is low inprofile.

Referring to FIGS. 15-17, an insulating insert 40 is disposed in thecell housing 22 between the electrode stack 64 and the cell housingfirst end 23. The insert 40 includes four rigid wall portions 41, 42,43, 44 arranged to form a closed, elongated rectangular section, anddimensioned to surround an end of the electrode stack 64. A shelf 45protrudes inward from an inner surface of each of the long wall portions42, 44 of the insert 40. The shelves 45 each include a lip 48 thatprotrudes toward the electrode stack 64. The lip 48 is spaced apart fromthe long wall portions 42, 44, and is configured to abut an outwardfacing surface 96 of the second outer plate 94. One of the shelves 45supports the base 123 of the second current collector connector 120(FIG. 14 The insert 40 also includes struts 46, 47 that extend betweenthe long wall portions 42, 44. The struts 46, 47 are located midwaybetween the short wall portions 41, 43, and are configured to surroundand protect internal structures associated with the gas relief valve 36and electrolyte inlet port 39. The insert 40 is formed of anelectrically insulating material such as plastic, and serves to isolatethe end (e.g., upper end with respect to the orientation shown in FIG.17) of the electrode stack 64, as well as to facilitate insertion of theelectrode stack 64 into the sidewall 25 of the cell housing 22.

Referring to FIGS. 18A and 18B, a method of manufacturing theabove-described electrochemical cell 20 will now be described. Aspreviously discussed, the cell 20 includes a rigid cell housing 22having the shape of a rectangular prism and an electrode assembly 60disposed in the cell housing 22. In initial method steps, the cellhousing first end 23, the cell housing second end 24 and the cellhousing sidewall 25 are provided as separate elements (steps 601, 602,603) that will be assembled together in subsequent method steps, asdescribed below.

The cell housing sidewall 25 is a rigid tube having a rectangularcross-sectional shape, and each of the cell housing first end 23, thecell housing second end 24 and the cell housing sidewall 25 are formedof an electrically conductive material such as metal. In the illustratedembodiment, the cell housing 22 is formed of aluminum. The cell housingfirst end 23 includes the pair of terminals 140, 142, as described abovewith respect to Figs, 13 and 14.

The electrode stack 64 of the electrode assembly 60 is also provided(step 604). To that end, the positive electrode plates 61 are stacked inan alternating manner with the negative electrode plates 62 andseparated by the separator 63. During the stacking procedure, thepositive electrode plates 61 and negative electrode plates 62 are offsetrelative to the separator 63 such that the clear lanes 56, 76 of therespective electrode plates 61, 62 protrude beyond a periphery of theseparator 63, and such that the positive electrode plates 61 are offsetin a direction opposed to the direction of offset of the negativeelectrode plates 62 (FIG. 3). In this configuration, the openings 58, 78of the respective electrode plates 61, 62 are disposed beyond aperiphery of the separator.

The insulating band 68 is then wrapped around the stacked arrangement ofpositive and negative electrode plates 61, 62 and separator so as totightly encircle the electrode stack 64 (step 605). The insulating band68 is dimensioned so that the clear lanes 56, 76 are not enclosed by theinsulating band 68, and instead protrude from, and are exposed at,opposed open ends of the insulating band 68. The insulating band 68maintains the electrode stack 64 in a compressed state in a directionparallel to the stack axis 66, and facilitates insertion of theelectrode stack 64 into the cell housing 22 during cell assembly, asdiscussed further below.

Prior to folding the respective clear lanes 56, 76, the electricallyconductive first inner plate 81 is inserted through the opening 58 inthe clear lane 56 of each of the positive electrode plates 61 (step606), and the electrically conductive second inner plate 91 is insertedthrough the opening 78 in the clear lane 76 of each of the negativeelectrode plates 62 (step 607) (FIG. 19). In some embodiments, aninsulating layer may be applied to the inward-facing surface of each ofthe first inner plate 81 and the second inner plate 91, for example byusing an adhesive insulating tape. Upon insertion through the respectiveopenings 58, 78, the first inner plate 81 and the second inner plate 91are disposed on opposed sides of the electrode stack 64, and each extendin a direction perpendicular to the positive and negative electrodeplates 61, 62. In some manufacturing processes, alternative method stepsmay be substituted for steps 605 and 606 that include providing thefirst and second inner plates 81, 91 in a spaced, parallel relationship,and stacking the electrode plates 61, 62 in an alternating manner bymounting the positive plates on the first inner plate via the openings58, and mounting the negative electrode plates 62 on the second innerplate 91 via the openings 78. The alternative method steps includearranging the separator 63 between adjacent electrode plates 61, 62 in aZ-folded configuration. This approach facilitates precise alignment ofthe electrode plates 61, 62.

After first inner plate 81 is disposed in the respective openings 58 ofeach positive electrode plate 61, the clear lane 56 of each positiveelectrode plate 61 is folded along a first fold line 59 that extendsalong a margin of the opening 58, in such a way that the clear lane 56overlies one side of the electrode stack 64 and the first inner plate 81(step 608). Similarly, after second inner plate 91 is disposed in therespective openings 78 of each negative electrode plate 62, the clearlane 76 of each negative electrode plate 62 is folded along a secondfold 79 line that extends along a margin of the opening 78, in such away that the clear lane 76 overlies an opposed side of the electrodestack 64 and the second inner plate 91 (step 609) (FIG. 11).

The electrically conductive first outer plate 84 is then disposed overthe folded positive clear lanes 56 such that the first outer plate 84overlies the first inner plate 81 and the positive clear lanes 56 aredisposed between the first outer plate 84 and the first inner plate 81(step 610). Likewise, the electrically conductive second outer plate 94is then disposed over the folded negative clear lanes 76 such that thesecond outer plate 94 overlies the second inner plate 91 and the secondclear lanes 76 are disposed between the second outer plate 94 and thesecond inner plate 91 (step 611) (FIG. 12).

Subsequent to placement of the first outer plate 84 over the foldedpositive clear lanes 56, the first inner plate 81, the folded positiveclear lanes 56, and the first outer plate 84 are electrically connectedtogether, for example via welding or other appropriate technique,whereby an electrical connection is formed between the first inner plate81, the folded positive clear lanes 56, and the first outer plate 84(step 612). In addition, subsequent to placement of the second outerplate 94 over the folded negative clear lanes 76, the second inner plate91, the folded negative clear lanes 76, and the second outer plate 94are electrically connected together, for example via welding or otherappropriate technique, to form an electrical connection between thesecond inner plate 91, the folded negative clear lanes 76, and thesecond outer plate 94 (step 613). As a result of these connecting steps611, 612, the electrode assembly 60 partially assembled. The electrodeassembly is inserted into the sidewall 25 in this partially assembledstate (e.g., prior to becoming fully assembled), as discussed below.

Prior to insertion of the partially assembled electrode assembly intothe sidewall 25, the insert 40 is placed on one end of the partiallyassembled electrode assembly (step 614). In particular, the insert 40 isarranged so that the wall portions 41, 42, 43, 44 surround the secondinner plate 91, the folded negative clear lanes 76, and the second outerplate 94, as well as adjacent portions of the electrode stack 64. Bythis configuration, the insert 40 protects the partially assembledelectrode stack as it is inserted into the sidewall 25.

The partially assembled electrode assembly and the insert 40 areinserted as a unit into the cell housing sidewall 25 (step 615). Duringinsertion of the partially assembled electrode assembly into thesidewall 25, the electrode stack 64 is oriented so that when it isdisposed within the cell housing 22, the stack axis 66 extends in adirection that is normal to, and passes through, each side 28, 29 of thepair of minor sides. In addition, the electrode stack 64 is oriented sothat the insert 40 provides the leading end during insertion, wherebythe insert 40 protects the electrode stack during insertion into thesidewall 25. The partially assembled electrode assembly and the insert40 are inserted through the sidewall 25 until the end of the insert 40is aligned with the end of the sidewall 25 (FIG. 17).

With the partially assembled electrode assembly and the insert 40disposed within the sidewall 25, the first leg 101 of the firstconnector 100 is electrically connected, for example via welding, to thefirst outer plate 84. In addition, the second leg 102 of the firstconnector 100 is electrically connected, for example via welding, to thecell housing second end 24 (step 616). Similarly, the first leg 121 ofthe second connector 120 is electrically connected, for example viawelding, to the second outer plate 94. In addition, the second leg 122of the second connector 120 is electrically connected, for example viawelding, to the terminals 140, 142 (step 617). In particular, the firsttab 122 a of the second leg 122 is electrically connected to the firstterminal 140, and the second tab 122 b of the second leg 122 iselectrically connected to the second terminal 142. As seen in FIG. 20,during steps 616 and 617, the cell housing first and second ends 23, 24are not yet connected to the cell housing sidewall 25, and the first andsecond connectors 100, 120 have a splayed configuration. Thisarrangement facilitates access to welding locations on the first andsecond connectors 100, 120, whereby the welding process is made easy andweld reliability is improved.

Once the electrical connections have be established between the firstcurrent collector assembly 80 and the cell housing second end 24 andbetween the second current collector assembly 90 and the terminals 140,142, the cell housing 22 is assembled. In particular, the firstconnector 100 is folded such that the first leg 101 overlies the secondleg 102 (618). As a result of the folding step 618, the cell housingsecond end 24 abuts, and closes, one open end of the cell housingsidewall 25. The second connector 120 is folded such that the first leg121 overlies the second leg 122 (step 619). As a result of folding step619, the cell housing first end 23 abuts the opposed end, and closes theopposed end, of the cell housing sidewall 25.

Following folding of the first connector 100, the cell housing secondend 24 is fixed, for example by welding, to the one end of the cellhousing sidewall 25 (Step 620). In addition, following folding of thesecond connector 120, the cell housing first end 23 is welded to theopposed end of the cell housing sidewall 25 (Step 621). In the weldingsteps 620, 621, a weld line is formed around the circumference of eachend of the cell housing sidewall to secure the respective first andsecond ends 23, 24 to the sidewall 25 and to fully assemble the cellhousing 22. As a result of the welding steps 620, 621, a closed interiorspace is formed within the cell housing 22, and the electrode assembly60 is disposed within the interior space.

In next steps, the cell housing 22 is filled with electrolyte via theelectrolyte inlet port 39 and sealed (step 622) to provide the cell 20,and formation of the cell 20 is then performed using conventionaltechniques (step 623).

In the illustrated embodiment, the cell housing 22 is formed of threeseparate elements, e the first end 23, the tubular sidewall 25 and thesecond end 24, which are joined together during manufacture to form asealed container. However, the cell housing 22 is not limited to thisconfiguration. For example, referring to FIG. 21, the cell 20 includesan alternative embodiment cell housing 322 that is formed of twoseparate elements, e.g., the first end 323 and a five-sided container325 which are joined together during manufacture to form a sealedcontainer. In the cell housing 322, the container 325 includes a tubularsidewall 325(25) that is formed integrally with the second end 325(24).Such a container 325 can be conveniently formed, for example in adrawing process. However, it may become challenging to form the weldedelectrical connections between the electrode stack 64 and the secondcurrent collector 90, and between the second current collector 90 andthe inner surface of the cell housing second end 325(24).

This challenge may be addressed by employing an alternative firstconnector 100′. The alternative first connector 100′ has a modifiedshape relative to the first connector 100 illustrated in FIG. 9. Forexample, the alternative first connector 100′ is U-shaped and thebase/fold edge is adjacent to, and parallel to, a minor side 29 of thecell housing 22. As a result, the alternative first connector 100′ haselongated first and second legs 101′, 102′ of sufficient length topermit welding of the first leg to the first outer plate 84 and weldingof the second leg to the inner surface of the integral second end325(24), where these welding steps occur prior to insertion of theelectrode stack 64 into the tubular sidewall 325(25).

The challenges associated with using a 5-sided container mayalternatively be addressed by modifying of the first connector 100 inshape and/or material so that it serves as a spring element thatprovides, an electrical connection between the first outer plate 84 andthe cell housing second end 325(24). The first connector 100 may bedisposed in the cell housing 325 in the above-described position betweenthe first outer plate 84 and the cell housing second end 325(24), but isnot welded to these elements. Instead, the first connector forms aweld-free, direct and pressured electrical contact with the cell housingsecond end 325(24) and first outer plate 84.

In yet another alternative, the challenges associated with using a5-sided container may be addressed by providing a direct, weld-freeelectrical connection between the electrode stack 64 and the cellhousing second end 325(24). For example, the first connector 100 of thefirst current collector assembly 80 may be omitted, and the first outerplate 84 directly contacts the cell housing second end 325(24), therebyforming an electrical connection with the cell housing second end325(24). As a result, the cell housing 322 has a positive polarity andserves as the positive terminal of the cell 20. In addition, the insert40 may be dimensioned to apply a force to the electrode stack 64 thaturges the electrode stack 64 toward the cell housing second end 24. Thisconfiguration also provides a weld-free electrical connection betweenthe first current collector assembly 80 and the cell housing second end325(24), where the electrical connection is made via direct physicalcontact. During manufacture of an alternative embodiment cell in whichthe first connector 100 is omitted, the method of manufacture will bemodified in that method steps 616, 618 and 620 may be omitted.

In the illustrated embodiment the cell housing 22 is formed of aluminumso as to permit connection with the positive electrode plates 61 via thefirst current collector assembly 80, which are also formed of aluminum.However, in some embodiments, the cell housing 22 may be formed of othermaterials, for example, nickel-plated steel. By forming the cell housing22 of nickel-plated steel, it becomes possible to connect either thepositive electrode plates 61 or the negative electrode plates 62 to thecell housing, and the other to the terminals 140, 142. Alternatively, itbecomes possible to connect the positive electrode plates 61 to one ofthe terminals (for example, the first terminal 140) and the negativeelectrode plates 62 to the other of the terminals (for example, thesecond terminal 142).

In the illustrated embodiment, the first current collector assembly 80,which is electrically connected to the positive electrode plates 61, iselectrically connected to the cell housing second end 24, whereby thecell housing 22 has a positive polarity. However, it is understood thatthe first current collector assembly 80 may alternatively beelectrically connected to the negative electrode plates 62, for exampleby rotating the electrode stack 64 within the cell housing by 180degrees about the stack axis 66, whereby the cell housing 22 would havea negative polarity. In such an alternative embodiment, the secondcurrent collector assembly 90 would be electrically connected to thepositive electrode plates 61, and provide an electrical connection tothe terminals 140, 142.

In the illustrated embodiments, the cell housing 22 includes twoindividual terminals 140, 142 that are supported on the cell housingfirst end 23. It is understood that the cell housing is not limited tohaving two individual terminals 140, 142. For example, in someembodiments, the cell housing 22 may instead include a single terminal440 (FIG. 22). Advantageously, use of a single terminal 440 provides anelectrically conductive contact portion 442 that is at least 75 percentof the area of the cell housing first end 23, and includes cut outs 443,445 to permit access to the vent and electrolyte inlet. In otherembodiments, the cell housing 22 may include more than two terminals(not shown).

In the illustrated embodiment, the second current collector assembly 90is electrically connected to the terminals 140, 142 via the secondconnector 120, which is welded to both the terminals 140, 142 and thesecond outer plate 94. However, in some embodiments, the electricalconnection between the terminals 140, 142 and the second currentcollector assembly may be a weld-free connection. For example, referringto FIG. 23, in some embodiments the second connector 120 may be replacedby an electrically conductive snap-fit connection assembly 500. Theconnection assembly 500 includes an electrically conductive connectorplate 510 that abuts the internal contact portion 170 of each terminal140, 140. The connector plate 510 includes shaped posts 502, 504 thatprotrude toward the electrode stack 64. The connection assembly alsoincludes electrically conductive spring clips 522, 524 that are fixed tothe outward-facing surface 96 of the second outer plate 94. The springclips 522, 524 are elastically deformable, and are shaped anddimensioned to receive and retain the shaped posts 502, 504 in asnap-fit manner. In the illustrated embodiment, the spring clips 522,524 each include a pair of legs 526, 527 having a shape that iscomplimentary to the shape of the shaped posts 502, 504. In addition,the legs 526, 527 are spaced apart a distance that is less than acorresponding dimension of the shaped posts 502, 504. When the shapedposts 502, 504 are inserted into the spring clips 522, 524, the legs526, 527 are deflected apart, and the elastic properties of the legs526, 527 as well as the complimentary shape of the legs 526, 527 andshaped posts 502, 504, serve to retain the shaped posts 502, 504 withinthe spring clips 522, 524, whereby the electrical connection between theterminals 140, 142 and the second current collector assembly is achievedvia a weld-free snap fit connection.

It is contemplated that, in addition to the exemplary cell embodimentsdescribed above, the cell 20 can be made to resemble a conventionalcell, for example a cell having one positive terminal disposed on thecell first end 23, and one negative terminal disposed on the cell firstend 23. This can be accomplished by only welding the negative terminalundersides to the copper current collector making that terminal negativeand connecting the positive terminal to the cover plate itself makingthat terminal positive.

Although the electrode assembly 60 is described herein as including aseries of stacked positive electrode plates 61 alternating with negativeelectrode plates 62 and separated by a z-folded separator 63, theelectrode assembly is not limited to this configuration. For example, insome embodiments, the electrode plates 61 may be separated from thenegative electrode plates 62 using individual separator plates.

Although the electrode assembly is described herein as being a “stacked”electrode assembly that includes a series of stacked plates, theelectrode assembly is not limited to this configuration. For example, insome embodiments, the electrode assembly may include a rolled electrodeassembly (e.g., a jelly roll assembly), a folded electrode assembly(i.e., a Z-fold assembly), or other electrode arrangement.

Although the cell housing 22 has an elongated rectangular shape in theexemplary embodiments, the cell housing 22 is not limited to this shape.For example, the cell housing may be cuboid in shape. In anotherexample, the cell housing may have other polygonal shapes that permitclose packing such as an eight surface structure having hexagonallyarranged sides (not shown).

Moreover, the cells 20 are not limited to being a lithium-ion battery.For example, the cells may be aluminum-ion, alkaline, nickel-cadmium,nickel metal hydride, or other type of cell.

Selective illustrative embodiments of the battery pack including thecell are described above in some detail. It should be understood thatonly structures considered necessary for clarifying these devices havebeen described herein. Other conventional structures, and those ofancillary, and auxiliary components of the battery pack and of the cell,are assumed to be known and understood by those skilled in the art.Moreover, while working examples of the battery pack and the cell havebeen described above, the battery pack and/or the cell are not limitedto the working examples described above, but various design alterationsmay be carried out without departing from the devices as set forth inthe claims.

What is claimed is,:
 1. A method of manufacturing an electrochemicalcell that comprises a rigid cell housing having the shape of arectangular prism and an electrode assembly disposed in the cellhousing, the method including the following steps: providing a cellhousing first end; providing a cell housing second end; providing a cellhousing sidewall in the form of a tube having a rectangularcross-sectional shape, the cell housing sidewall formed separately fromeach of the cell housing first end and the cell housing second end;inserting the electrode assembly into the cell housing sidewall; weldingthe cell housing first end to one end of the cell housing sidewall; andwelding the cell housing second end to an end of the cell housingsidewall opposed to the one end of the cell housing sidewall.
 2. Themethod of claim 1, wherein the electrode assembly comprises positiveelectrode plates alternating with negative electrode plates andseparated by at least one separator to form an electrode stack, whereinthe electrode assembly defines a stack axis that extends parallel to astacking direction of the positive electrode plates, the negativeelectrode plates and the at least one separator, the cell housingsidewall includes a pair of major sides joined by a pair of minor sides,where each side of the pair of major sides is larger in area than eachside of the pair of minor sides, and the step of inserting the electrodeassembly into the cell housing sidewall includes orienting the electrodestack within the cell housing such that the stack axis extends in adirection that is normal to, and passes through, each side of the pairof minor sides.
 3. The method of claim 1, wherein the electrochemicalcell comprises a connector disposed in the cell housing between theelectrode assembly and the cell housing first end, the method comprisingelectrically connecting one end of the connector to a terminal thatprotrudes through the cell housing first end; electrically connectinganother end of the connector to an electrode plate of the electrodeassembly; and folding the connector such that the one end of theconnector overlies the another end of the connector, and such that thecell housing first end abuts the one end of the cell housing sidewall.4. The method of claim 3, wherein the method steps of claim 3, whichinclude electrically connecting one end of the connector to a terminalthat protrudes through the cell housing first end; electricallyconnecting another end of the connector to an electrode plate of theelectrode assembly; and folding the connector such that the one end ofthe connector overlies the another end of the connector, and such thatthe cell housing first end abuts the one end of the cell housingsidewall, are performed before the method step of welding the cellhousing first end to one end of the cell housing sidewall.
 5. The methodof claim 1, wherein the electrode assembly comprises positive electrodeplates alternating with negative electrode plates and separated by atleast one separator, each of the positive electrode plates comprise anelectrically conductive first substrate; a first coating disposed on thefirst substrate, where the first coating is formed of a first activematerial; a first clear lane that is disposed along an edge of thepositive electrode, plate, the first clear lane being free of the firstcoating; and a first opening disposed within the first clear lane, eachof the negative electrode plates comprise an electrically conductivesecond substrate; a second coating disposed on the second substrate,where the second coating is formed of a second active material; a secondclear lane that is disposed along an edge of the negative electrodeplate, the second clear lane being free of the second coating; and asecond opening disposed within the second clear lane; and the methodincludes the following method steps: inserting an electricallyconductive first inner plate through each first opening such that thefirst inner plate extends in a direction perpendicular to each positiveelectrode plate, and is electrically connected to at least one of thepositive electrode plates, and inserting an electrically conductivesecond inner plate through each second opening such that the secondinner plate extends in a direction perpendicular to each negativeelectrode plate, and is electrically connected to at least one of thenegative electrode plates.
 6. The method of claim 5, thither comprisingfolding each positive electrode plate along a first fold line thatextends along a margin of the opening, whereby the first clear laneoverlies a side of the electrode stack and the first inner plate; andfolding each negative electrode along a second fold line that extendsalong a margin of the opening, whereby the second clear lane overlies aside of the electrode stack and the second inner plate.
 7. The method ofclaim 6, further comprising disposing an electrically conductive firstouter plate over folded first clear lanes such that the first outerplate overlies the first inner plate and the first clear lanes aredisposed between the first outer plate and the first inner plate, anddisposing an electrically conductive second outer plate over foldedsecond clear lanes such that the second outer plate overlies the secondinner plate and the second clear lanes are disposed between the secondouter plate and the second inner plate.
 8. The method of claim 7,further comprising welding the first inner plate, the folded first clearlanes, and the first outer plate together to form an electricalconnection between the first inner plate, the folded first clear lanes,and the first outer plate, and welding the second inner plate, thefolded second clear lanes, and the second outer plate together to forman electrical connection between the second inner plate, the foldedsecond clear lanes, and the second outer plate.
 9. The method of claim8, further comprising electrically connecting the first outer plate to aterminal that protrudes through the cell housing and is electricallyisolated from the cell housing, and electrically connecting the secondouter plate to the cell housing.
 10. The method of claim 9, wherein afirst connector is used to electrically connect the first outer plate tothe terminal, and a second connector is used to electrically connect thesecond outer plate to the cell housing.
 11. The method of claim 9,wherein a connector is used to electrically connect the first outerplate to the terminal, and the second outer plate is electricallyconnected to the cell housing via direct contact with the cell housing.12. The method of claim 1, wherein the electrode assembly comprisespositive electrode plates alternating with negative electrode plates andseparated by at least one separator, each of the positive electrodeplates and the negative electrode plates including an electricallyconductive substrate; a coating disposed on the substrate, where thecoating is formed of an active material; a clear lane that is disposedalong an edge of the substrate, the clear lane being free of thecoating; and an opening disposed within the clear lane, the methodincluding the following method steps: inserting an electricallyconductive inner plate through each opening of at least one of thepositive electrode plates and the negative electrode plates such thatthe inner plate extends in a direction perpendicular to each substrate,and is electrically connected to the substrate.
 13. The method of claim12, further comprising folding each electrode plate of the at least oneof the positive electrode plates and the negative electrode plates alonga first fold line that extends along a boundary between the coating andthe clear lane, whereby the clear lane overlies a side of the electrodestack and the inner plate.
 14. The method of claim 13, furthercomprising disposing an electrically conductive outer plate over thefolded clear lanes such that the outer plate overlies the inner plateand the clear lanes are disposed between the outer plate and the innerplate.
 15. The method of claim 14, further comprising welding the innerplate, the folded clear lanes, and the outer plate together to form anelectrical connection between the inner plate, the folded clear lanes,and the outer plate,
 16. The method of claim 15, further comprisingelectrically connecting the outer plate to one of a cell housing and aterminal that protrudes through the cell housing, where the terminal iselectrically isolated from the cell housing.
 17. The method of claim 16,wherein a connector is used to electrically connect the outer plate tothe one of a cell housing and a terminal.
 18. The method of claim 1,wherein the first end, the second end and the sidewall are provided asthree individual and separate elements, the electrode assembly includespositive electrode plates alternating with negative electrode plates andseparated by at least one separator to form an electrode stack, theelectrode assembly includes a first current collector including a firstconnector that electrically connects the positive electrode plates to apositive terminal, and the electrode assembly includes a second currentcollector including a second connector that electrically connects thenegative electrode plates to a negative terminal.
 19. The method ofclaim 1, wherein the second end and the sidewall are provided as asingle integral entity, and the first end is provided as a separateelement from the integral sidewall and second end, the electrodeassembly includes positive electrode plates alternating with negativeelectrode plates and separated by at least one separator to form anelectrode stack, the electrode assembly includes a first currentcollector including a first connector that electrically connects one ofthe negative electrode plates and the positive electrode plates to firstterminal, and the electrode assembly includes a second current collectorthat is connector free and forms a weld-free electrical connectionbetween the other one of the the negative electrode plates and thepositive electrode plates and a second terminal.